Mask Sheet Fixation Structure for Precise Display Deposition
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Solution Overview
Problem
Existing display device manufacturing methods face challenges in precisely depositing deposition materials onto substrates of varying sizes due to limitations in mask assembly design, leading to potential substrate damage and reduced product quality.
Innovation Solution
A mask assembly with a mask frame, support member, and mask sheet featuring uneven edge portions and holes, where the mask sheet is tensioned and fixed using a welding process, allowing for precise guidance of deposition materials onto substrates of different sizes without causing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask sheet is fixed to a support member using conventional methods, then the mask sheet can be held in place, but the mask sheet deforms and cannot be tensioned properly
Solution Approach 1:
The support member incorporates grooves at specific locations where the mask sheet is to be fixed. These grooves provide localized structural support and constraint, allowing the mask sheet to be tensioned at specific points without deforming the entire sheet. The grooves create localized fixation zones that maintain the overall tension and flatness of the mask sheet.
Solution Approach 2:
The mask sheet is designed with an asymmetric structure featuring a body portion and a protruding portion. The protruding portion extends beyond the body portion and is specifically positioned to engage with the grooves on the support member. This asymmetric design allows one-sided fixation where the mask sheet is held from one side only, enabling proper tensioning while preventing deformation.
2Manufacturing precision
If mask sheets of various sizes are used to guide deposition material, then deposition precision can be improved, but the complexity of mask assembly increases
Solution Approach 1:
The support member is designed as a universal component that can accommodate mask sheets of various sizes. The grooves on the support member are positioned and dimensioned to work with different mask sheet configurations. This allows a single support member design to serve multiple functions across different substrate sizes, eliminating the need for multiple specialized mask assemblies and reducing overall system complexity.
3Measurement precision
If the mask sheet is fixed tightly to the support member, then positioning accuracy is improved, but substrate damage risk increases due to deformation
Solution Approach 1:
Instead of fixing the entire mask sheet uniformly to the support member, the grooves provide localized fixation only at the edges or specific critical points. This localized fixing approach achieves sufficient positioning accuracy for deposition while avoiding excessive tension across the entire mask sheet that would cause deformation and substrate damage.
Solution Approach 2:
The fixation system is segmented into discrete groove locations rather than continuous contact. The mask sheet is fixed at specific segmented points along its perimeter or critical areas, allowing the rest of the sheet to remain relatively free and reduce deformation forces transmitted to the substrate during deposition.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables precise and efficient deposition of materials onto substrates, reducing substrate damage and improving product quality by minimizing deformation and ensuring accurate material distribution across varying display areas.
Implementation Method 1
The mask sheet may be fixed to the support member by a welding process
Data Source
AI summary
Provided are a mask assembly and a manufacturing method thereof, and an apparatus and a method of manufacturing a display device. The mask assembly includes a mask frame including an opening region, a support member disposed on the mask frame to divide the opening region into at least two, and a mask sheet disposed on the support member to overlap the opening region and including uneven edge portions and a plurality of holes.